A Gasket

ABSTRACT

Gaskets for sealing two mating surfaces are described. The gaskets have an outer portion including a core between two sealing layers and an inner portion made of a deformable material and located in an aperture in the outer portion. The thickness of the inner portion is greater than the thickness of the outer portion. The inner portion may include a chemical treatment agent that can provide chemical protection to the mating surfaces. Methods of producing the gaskets and methods of using the gaskets for sealing joints, including corroded joints, are also described.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of Great Britain Patent ApplicationNo. 0922625.9 filed on Dec. 24, 2009, the contents of which areincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to gaskets, in particular, but notexclusively, flange joint sealing gaskets with an especiallyadvantageous application as a replacement flange joint sealing gasket.

BACKGROUND

The use of gaskets in sealing applications is commonplace in manyindustries. A well known application for gaskets is to provide fluidsealing between two mating surfaces such as between two ends ofadjoining pipes or conduits where they are commonly in the form of aflange joint for ease of assembly and disassembly and for bettersealing. A flange joint sealing gasket usually comprises a compressiblering defining an aperture of a size that matches the conduit beingsealed and a body that matches the dimensions of the flange matingsurfaces. In many applications however the flange joint mating surfaceswhich are typically metal eventually become damaged either by internalchemical corrosion, erosion or external weathering. This attrition ofthe surface can cause pitting, crevices and other imperfections to formon the surface. In such cases, replacement of an ordinary sealing gasketwill not be sufficient to effect adequate sealing under operationalpressures because the surface imperfections may provide fluid escapepathways and weak points in the surface sealing. As a consequence, itmay become necessary to replace or repair the flanges or even the wholeflanged pipe to reestablish or improve sealing performance.

In high pressure sealing applications, one preferred gasket has what isknown as a Kammprofile core. This is effectively a gasket with a seriesof concentric serrations or a concertina-like profile on one or bothfacing surfaces. The profile is superimposed onto a solid core, usuallymetal, by the series of concentric serrations. During the sealingprocess the overlying softer sealing material is forced into the gapsbetween serrations to improve sealing by inducing stress concentrationson the sealing surfaces. The serrations also minimise lateral movementof the facing material, while the metal core provides rigidity andblowout resistance. Such a profile gives the gasket added strength forhigh pressure applications. As mentioned, such a gasket also includes asuitable compressible sealing material that is coated over theKammprofile core. However, in cases of mating surfaces which have becomepitted or corroded even such high pressure gaskets cannot always provideadequate sealing. It is an object of the present invention to provide animproved gasket suitable for such applications but also having widerapplications for corroded or otherwise damaged mating surfaces.

U.S. Pat. No. 6,092,811 relates to a corrugated gasket core that usesinner and outer laminate materials. The inner material is designed to bechemically resistant to protect the outer material from chemical attack.The use of these gaskets to seal parallel mating surfaces includingscratched or pitted surfaces is discussed but no mention of including achemical treatment agent into the material or the possibility ofsimultaneously chemically protecting the damaged surfaces of the gasketsis mentioned.

Methods of coating the inner edge of a gasket with another sealingmaterial usually a polymer or inorganic sealant are described in U.S.Pat. No. 6,093,467, US 2004/0007828 and US 2003/0230856. The possibilityof the polymeric coating being of a greater depth to enhance sealing isdisclosed as is the possibility of use with a damaged surface. However,no mention of chemically protecting the mating surfaces is mentioned.

SUMMARY

According to a first aspect of the present invention there is provided agasket for sealing two mating surfaces having: —

a) an outer portion comprising a core interposed between sealing layers,the outer portion defining a first aperture therein, the core and/or thesealing layers defining an inner edge of the outer portion, the saidinner edge immediately surrounding the first aperture;b) an inner portion comprising deformable material defining a secondaperture therein, the inner portion having an inner edge defining thesecond aperture and an outer region designed to be secured to the outerportion so that the inner portion is held securely by the outer portion,the thickness of the inner portion being greater than the thickness ofthe outer portion so that in use the inner portion deforms to a greaterextent than the outer portion, and wherein the deformable inner portionincludes a chemical treatment agent operable to provide chemicalprotection on the surfaces of mating surfaces to be sealed.

The chemical treatment agent may thus be applied to the component matingsurfaces to simultaneously treat the surface during sealing.

Preferably, the outer region of the inner portion is defined by theouter edge of the inner portion which is designed to be continuouslyclose fitting with the inner edge of the outer portion.

However, alternatively, the outer region of the inner portion mayoverlap the inner edge of the outer portion and be secured to the upperand lower surfaces thereof. In such cases, the inner portion may be inthe form of a laminate which is applied and secured to both surfaces ofthe outer portion at the overlapping outer region of the inner portionand is then merged together at least at the inner edges of the innerportion to define the second aperture. In such cases, at least a portionof the outer portion is not so overlapped. In any case, it will beapparent that the second aperture is smaller than and located within thefirst aperture.

Additionally or alternatively it is possible to secure the inner portionto the outer portion by suitable fixing means. The fixing means mayextend from the core to secure the two portions together. For thispurpose the fixing means is preferably arranged so that it does not comeinto contact with the two mating surfaces in use. One possibleembodiment for this purpose is to embed the fixing means in the outerand/or inner portion in such a manner that it extends in the plane ofthe gasket. Typically, the fixing means may be embedded in the outerportion in the sealing layer, between the sealing layer and the core oreven in the core and/or it may be embedded in the inner portion. Atleast the outer region of the inner portion may be designed toaccommodate such a fixing means. Preferably, for secure fixation, thefixing means may extend inwardly from the core, preferably, the inneredge thereof, in the plane of the gasket and into the inner portion. Thefixing means may be integral with the core and may be co-planartherewith at the axial ends thereof. Preferably, the fixing means is aradially inwardly extending projection from the inner edge of the core.Typically, the radially innermost end of the projection extends part waythrough the inner ring in the plane of the gasket to thereby secure theinner ring to the outer ring. The accommodating socket for theprojection in the inner ring may be formed by the projection or formedseparately. Typically, there are at least two such projections, morepreferably, at least three, most preferably, at least four.Conveniently, in this embodiment the core and projections may be pressedfrom the same sheet material for instance by using a punch press and/orby laser cutting.

Preferably, however, the outer portion is in the form of a Kammprofilegasket which provides a solid inner edge defining the first aperture andagainst which the outer edge of the inner portion can engage to providea strong abutment in use. Thus the outer portion core may comprise asolid metal core having a series of serrations formed on the facingsurfaces thereof. A suitable groove profiler machine may be used to formthe serrations on the core.

Preferably, the chemical treatment agent is a corrosion treatment agent,more preferably a rust inhibitor. Typically, the chemical treatmentagent is present in the deformable inner portion in a range of 0.01% to50% w/w, more preferably, 0.1% to 20% w/w, most preferably, 0.5% to 5%w/w.

By chemical protection is meant the provision of chemical agents toprevent chemical attack and this does not include providing physicalprotection against chemical attack such as by sealing of the matingsurface to prevent ingress of fluid.

It will be clear from the foregoing that the chemical treatment agentwill be in contact with at least one and preferably both mating surfacesin use. Accordingly, the chemical treatment agent is included in such amanner that it is available on the surfaces of the inner portionmaterial that will be in contact with the mating surfaces in use.Preferably, it is available on the majority, more preferably,substantially all of the surface of the inner portion that will be incontact with the mating surfaces in use.

Preferably, the material of the inner portion is more compressible thanthe sealing layer of the outer portion. Suitable sealing materials forthe outer portion include PTFE, graphite, Thermiculite (or suitablevermiculite based sealing material), non-asbestos sheet, or a softmetallic face such as silver or tin, preferably, PTFE is used. The PTFEis preferably biaxially orientated. In particular, the biaxiallyorientated PTFE is preferably filled with hollow glass microspheres.Such a material is available from Flexitallic under trade name Sigma500.

Biaxially orientated PTFE containing hollow glass microspheres hasadvantages over pure or filled PTFE and envelope gaskets by reducingcold flow.

Biaxially orientated PTFE is generally produced by producing a slurry ofPTFE particles in a volatile solvent, optionally with fillers, dyesand/or other suitable gasket additives such as the glass microsheresmentioned above. After draining, a sheet of pliable mass is fomed whichis rolled in two different mutually perpendicular directions to causethe PTFE particles to fibrillate and create a network of biaxiallyorientated fibres in two different directions, generally at right anglesto each other. The technique is well known to the skilled person and wasoriginally developed by Du Pont and is disclosed in GB 1,049,328.

Suitable non asbestos sheets are generally made by compressing andalendaring synthetic fibre, natural rubber, a suitable gasket filler andoptionally, a dye. Suitable fillers will be known to the skilled personand may be selected from: —talc, clay, calcium carbonate, silica etc

Suitable synthetic fibres will be known to the skilled person and may beselected from: —aramid, glass fibres, mineral fibres and carbon fibres.

By “soft” metallic face is meant a metal having a hardness less than 3.0or less than copper on the Mohr hardness scale.

Suitable sealing materials for the inner portion include PTFE, whereinthis PTFE is preferably softer than the PTFE of the outer part, whenused, more preferably a highly compressible biaxially orientatedmicrocellular PTFE based material.

As mentioned above the inner portion is preferably more compressiblethan the outer portion so that in use the inner material is onlycompressed as far as the less compressible outer portion will allow.

The compression of the respective sealing materials may be measured byASTM F36. Preferably, the compression of the outer portion falls withinthe range 5-50% compression, more preferably, 10-40%, most preferably,20-30% compression, in use. In any case, the outer portion willtypically have less than 50% compression, more preferably <40%compression, most preferably, <30% compression with reference to theoriginal thickness.

Typically, the compression of the inner portion is within the range30-90% compression in use, more typically, 40-80%, most typically,between 50-70% compression. In any case, the inner portion willtypically have more than 30% compression, more typically, more than 40%compression and most typically more than 50% compression in use. In anycase, the inner portion compression is preferably greater than the outerportion.

Suitable sealing materials for the inner portion include those havingthe above compression characteristics, particularly those which arerelatively chemically inert. A suitable material is a microcellularbiaxially oriented PTFE which has been produced with a water solublefiller that can be washed out after sintering of the PTFE material toproduce a hollow microcellular structure. Such a production technique isknown to the skilled person. Such a material can then be washed with asolution of the chemical treatment agent followed by drying to therebyimpregnate the microcellular structure of the PTFE material. Repeatedwashing and drying steps or variation in the solution concentration canbe used to effect the required concentration in the final gasketeffective to produce an improvement to the flange joints in the finalapplication. A material suitable for such impregnation is available fromFlexitallic under trade name Sigma 600.

Preferably, the inner portion deformable material is inherently morecompressible than the sealing layer material, typically, at least 10%more compressible, more typically, at least 20% more compressible, mosttypically, at least 50% more compressible in the axial direction undernormal operating pressures.

Advantageously, the material of the inner portion allows it to becompressed into any imperfections in the mating surface thus at leastpartially filling any scratches, crevices or pits in the surface. Bythis means, a very efficient delivery mechanism to the surfaceimperfections for the chemical treatment agent is achieved at the sametime as the surface imperfections are sealed from further attack by theinner portion deformable material. Thus a separate chemical treatmentcoating step for the mating surface is not required. By impregnating thematerial of the inner portion with a chemical treatment agent such as arust inhibitor, further corrosion of the damaged areas is reduced byspecifically applying rust inhibitor into scratches, crevices and pitsusing the compressibility of the inner portion as the delivery agent.Still further, the inner material has the effect of micro-sealing theimperfections in the mating surfaces by forming a seal around the edgeof the surface imperfection with the rest of the mating surface thussealing the imperfection in with the impregnated surface of the innerportion material.

According to a further aspect of the present invention there is provideda method of sealing two substantially parallel surfaces, comprising:interposing between the said surfaces a gasket according to the firstaspect of the present invention;

positioning said gasket between the two substantially parallel surfaces;andsecuring said parallel surfaces together to thereby deform the innerportion of the gasket against the said parallel surfaces.

According to a further aspect of the present invention there is provideda method of sealing and simultaneously coating/treating mating surfaceswith a gasket comprising the steps of locating a gasket according to thefirst aspect of the present invention on the mating surface to be sealedand securing the gasket in position so that the inner ring is compressedand the chemical treatment agent is delivered to the mating surfaces.

Preferably, the mating surfaces have been damaged by corrosion.

A method of producing a gasket according to the first aspect of thepresent invention comprising: —

providing a core according to the first aspect of the present invention,coating the core on upper and lower faces with a core sealing layer toprovide an outer portion according to the first aspect of the presentinvention andlocating a close fitting inner portion according to the first aspect ofthe present invention around the inner edge of the outer portion.

Preferably, the inner portion material can be compressed to between10-90% of its original thickness under normal operating pressures, morepreferably, it may be compressed to 20-85% of its original thicknessunder such pressures, most preferably, it may be compressed to between50-75% of its original thickness.

Generally, the inner portion material is a core free material andtypically, the deformable material including the treatment agent formsthe entire inner portion. However, in an alternative embodiment it mayoverlap with the core of the outer portion as mentioned above.

By normal operating pressures is meant between 100 Kpa-43000 Kpa, moretypically, 1000 Kpa-20000 Kpa. As mentioned above, the inner portionouter edge is preferably designed for close fitting engagement with theinner edge of the outer portion, typically, this is provided by a pushfit arrangement which is usually satisfactory because of the resilientlydeformable nature of the inner portion which allows it to be compressedsufficiently to provide a sufficiently strong seal at the junction ofthe inner and outer portion.

For most flange gasket applications with ring shaped flanges both theinner portion and the outer portion are also in the form of rings.Typically, the outer edge of the outer portion is designed to becoextensive with the flange outer edge. However, in some embodiments,the outer edge may be defined by the mating surfaces and the outerportion of the flange may extend further to accommodate fixingcomponents such as bolts etc. In a still further embodiment, however,the gasket may be designed to accommodate such fixings through the bodyof the gasket too.

In a still further embodiment, the gasket may include an outwardlyextending extension to the gasket to allow the gasket to be held by thefitter whilst being secured in position in a joint. Generally, theextension does not form part of the gasket unlike lugs found on somegaskets having apertures for joint fixation devices such as bolts topass therethrough and thereby secure both the gasket and the faces ofthe joint. In fact, in a preferred embodiment, the extension is securedto such a fixation lug which itself extends integrally from the outercore of the gasket. Once the gasket is secured in position the extensionwhich is located outside the joint may be removed. Accordingly, theextension is preferably frangible for this purpose. However, anysuitable attachment means for the extension may be utilised as long asit can be removed after the gasket is secured in position in the joint.A suitable embodiment includes a generally co-planar T-shaped extensionsecured at its base to the outer edge of the outer portion or,optionally, a fixation lug by one or more frangible thin sections. Thethin sections are strong enough to keep the extension attached to themain gasket during normal storage, transport and fitting conditions butweak enough to allow easy removal under a suitable force applied by theuser after joint fixation. The handle extension also provides aconvenient means to locate the gasket in the correct position in thejoint. This can be particularly advantageous in subsea locations wherethe maintenance diver needs to avoid entrapment in the event ofunexpected joint closures. For storage and transport reasons, theextension is generally co-planar with the main gasket body but it mayalso be advantageous for the extension to extend from the outer portionat a small angle to the plane of the gasket of about 1 to 60°, morepreferably, 1 to 30°.

In one embodiment, the extension is secured to the core, optionally viaa fixation lug, and preferably consists of the same material. Thisallows the core and extension to be cut or punched therefrom as a singlepiece.

Preferably, the core of the present invention is designed to be suitablefor the operating pressures under which the gasket will be used. Aparticularly advantageous core design is one having serrated ridges or aconcertina-like profile on the facing surfaces of a solid metal core.Such gaskets cores are well known in the art of gaskets and aredescribed as Kammprofile gaskets.

Suitable materials for the core are stainless steel, alloy 400, othersuitable Monel alloys, carbon steel or other suitable metal to match theparallel surfaces to be sealed.

It will be appreciated that although one particularly useful applicationof the present invention is in the field of flange gaskets which havebecome corroded due to exposure to sea water, the invention has otherapplications generally in the field of gaskets where two metal surfacesare mated together and one or both of the surfaces has become corrodedor otherwise pitted or damaged by chemical attack. Clearly, the chemicaltreatment agent is selected to fill and simultaneously treat the damagedareas. For instance, a flange that was subject to acid attack mayrequire a neutralising agent or buffer that might resist the acidattack. Similarly, caustic attack can be treated with a correspondingneutralising agent or an alkali buffer. Further applications may includesurfaces exposed to oxidising or reducing agents and the correspondingchemical agents can be selected accordingly.

Advantageously, even if the gasket of the invention is not impregnatedwith a chemical treatment agent but the mating surfaces have becomecorroded to the extent that normal gaskets allow unacceptable leakage, agasket according to the invention can improve the leakagecharacteristics of the joint. This is brought about by the greaterthickness and hence deformation of the inner portion assisting thesealing of the corroded surface. Thus by use of the device of thepresent invention extended joint life can be achieved, particularly incorroding environments.

Thus according to a further aspect of the present invention there isprovided a gasket for sealing two mating surfaces having: —

a) an outer portion comprising a core interposed between sealing layers,the outer portion defining a first aperture therein, the core and/or thesealing layers defining an inner edge of the outer portion, the saidinner edge immediately surrounding the first aperture;b) an inner portion comprising deformable material defining a secondaperture therein, the inner portion having an inner edge defining thesecond aperture and an outer region designed to be secured to the outerportion so that the inner portion is held securely by the outer portion,the thickness of the inner portion being greater than the thickness ofthe outer portion so that in use the inner portion deforms to a greaterextent than the outer portion.

Preferably, the deformable inner portion includes a chemical treatmentagent operable to provide chemical protection on the surfaces of matingsurfaces to be sealed. In addition, the gasket of this aspect mayinclude any one or more of the optional, preferred or typical featuresof the gaskets of other aspects

Therefore, the invention also extends to a method of sealing twosubstantially parallel surfaces, comprising:

interposing between the said surfaces a gasket according to this furtheraspect; positioning said gasket between the two substantially parallelsurfaces; andsecuring said parallel surfaces together to thereby deform the innerportion of the gasket against the said parallel surfaces. Preferably, atleast one of the parallel surfaces has been corroded to such an extentthat significant leakage occurs if a normal gasket, for example, oneconsisting of only an outer portion according to part (a) of this aspectof the invention but defining the second aperture therein rather thanthe first aperture, is secured between the said parallel surfaces.

Additionally, the invention extends to a method of producing a gasketaccording to this aspect of the present invention comprising: —

providing a core according to this aspect of the present invention,coating the core on upper and lower faces with a core sealing layer toprovide an outer portion according to this aspect of the presentinvention andlocating a close fitting inner portion according to this aspect of thepresent invention around the inner edge of the outer portion.

Furthermore, the invention extends to the use of a gasket according tothis aspect as a sealing gasket for corroded parallel surfaces,typically joints, especially, flange joints,

In accordance with any aspect of the invention a preferred material forthe sealing coating on the core material and the inner deformablematerial is biaxially structured PTFE. Typically, the inner material hasa microcellular structure and is impregnated with the selected chemicalagent such as corrosion inhibitor.

Impregnation of the inner portion material may be carried out bydipping, spraying, brush coating or any suitable technique known in thecoating art. The inner portion material may be coated prior to being cutinto the required gasket shape.

A suitable rust inhibitor for the present invention may be selected fromthe list consisting of: —suitable salts of phosphates, molybdates,nitrites, borates, phosphonates or other iron chelating or sequesteringagents. Typical chelating agents include EDTA (ethylenediaminetetraacetic acid), HEDTA (hydroxyethylenediamine triacetic acid), NTA(nitriolotriacetic acid) and citric acid. Preferably, a metal salt ofEDTA is selected such as an alkali, alkaline earth metal salt, mostpreferably a sodium EDTA salt. An aqueous solution of an EDTA salt maybe used to apply the EDTA salt. A suitable concentration thereof willdepend on the application but a typical range will be 1-10000 g/m³, moretypically, 10-5000 g/m³, most typically, 200-2000 g/m³.

Preferably, the inner portion material compressibility is selected so asto cause it to make intimate contact in the crevices and other corrosionbased defects in a flange surface, the benefit of this is firstly thatit will make a good seal which is important for a gasket, but secondlywhere there is a corrosion cell it can passivate the cell by allowingthe EDTA (or other) anion to react with iron (in the crevice on theflange surface), thus cutting off the corrosion reaction. Also, in thepresence of water (and the potential beginning of a corrosion cell) theanion can be released and react with any iron available on the flangesurface, passivating it, and thus making it more difficult for acorrosion cell to initiate.

The invention will now be described by way of illustration only withreference to the accompanying drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is An exploded perspective view of a gasket of the presentinvention showing the separate components.

DETAILED DESCRIPTION

Referring to FIG. 1, a corrugated gasket core 2 is shown having acorrugated area 8 extending outwardly from an inner edge 10 defining afirst aperture 14 to a plane surfaced outer area 12. The core 2 is shownprior to complete covering of the upper and lower surface of thecorrugated area 8 with respective PTFE sealing rings 4, 6 having inneredges 16 a, 16 b which also define the first aperture 14 and outer edges18(a), 18(b) which terminate at the outer edge of the corrugated area 8when affixed to the surface of the core. The core 2 includes handlinglugs 20, 22 extending outwardly from the plane surface area 12 onopposite sides of the gasket core. Each lug 20, 22 is integral with thecore and has a centrally disposed hole 32, 34 to accommodate a fixingbolt (not shown) when locating the gasket in the flange joint.

The gasket includes an inner ring 24 defined by an inner edge 26 whichitself defines a 2^(nd) aperture 30 and an outer edge 28 which is shapedfor close fitting engagement with the inner edges of the gasket core 10and outer sealing rings 16(a) and 16(b). The axial depth of the innerring 24 is roughly twice that of the assembled outer ring and it islocated in such a manner that it extends beyond the surface of the outerring equally in both axial directions.

In one embodiment, the inner ring 24 is made of expanded PTFE polymerwhich is microcellular in structure and which has been fully immersed ina rust inhibiting aqueous solution of sodium EDTA having a concentrationof 200 g/m³.

In a further embodiment (not shown), the core includes four equallycircumferentially spaced, radially inwardly extending projections,integral with the core and co-planar therewith at the axial endsthereof. The radially innermost end of the projection extends part waythrough the inner ring in the plane of the gasket to thereby secure theinner ring to the outer ring. The inner rings includes four matchingcircumferentially spaced sockets to accommodate each of the fourprojections in the inner ring.

In a still further embodiment (not shown), one of the lugs 20,22includes a generally co-planar T-shaped extension secured at its base tothe radially outermost edge of the lug by one or more frangible thinsections. The thin sections are strong enough to keep the extensionattached to the main gasket during normal storage, transport and fittingconditions but weak enough to allow easy removal under a suitablegenerally axial force applied by the user after joint fixation.

In use, in one embodiment, the gasket is located between two matingparallel surfaces of a flange connection on a pipe connection whereinthe surfaces of the flange have been corroded by prolonged exposure tosea water. As the mating surfaces are pressed together the deformablePTFE polymer of the inner is compressed and pushes into the crevices,scratches and pits in the surface of the flange providing sealingthereof and also delivering the sodium EDTA to the corroded areas. Atthe same time, the PTFE inner ring is also sealed against the undamagedareas on the surface and simultaneously treats those surfaces with rustinhibitor providing future resistance to rusting.

In one embodiment, the gasket is produced by cutting the appropriategasket shape of the solid stainless steel core and machining a series ofconcentric serrations of increasing radii from the inner edge thereofwhich defines a first central aperture. The serrations are terminatedbefore reaching the outer edge of the solid steel core so that an outerborder of non-serrated profile is provided on the gasket. An annularring of PTFE biaxially orientated compressible sealing material sized soas to fit over the serrated ring portion of the gasket is then cut and asuitable adhesive is applied to the inner face thereof. An annular ringof Sigma 500 PTFE is applied to both serrated areas on opposite faces ofthe core to thereby provide the outer gasket. An inner ring of highlycompressible biaxially orientated PTFE, produced by impregnating asuitable sample of Sigma 600 available from Flexitallic with a rustinhibiting aqueous solution of sodium EDTA having a concentration of 200g/m³ followed by drying is then cut having an outer edge of the sameradius as the inner edge of the core and an inner edge which defines the2^(nd) aperture. Typically, the depth of the inner ring material isapproximately twice that of the outer ring. In one embodiment, the depthof the inner ring is 6.5 mm and the depth of the outer ring is 3.5 mmmade up of a 2 mm thick core and two facing layers each of 0.75 mmthickness. The depth of the serrations on the core is typically about300 to 400 microns. For larger nominal pipe size flanges, or where outof flatness issues exist, the usage of thicker inner rings may bebeneficial up to and including 10 mm. For certain flanges, the usage ofa thicker core may also be advantageous.

In one embodiment, the metallic core is serrated in the area ofapplication of the Sigma 500 material; in all other external areasoutside the sealing contact areas the metallic core is protected andcovered by a layer of Fluoro Polymer (FP) based coating this canoptionally include the inner and outer edges of the metallic core. Thesealing faces should be masked during coating to avoid contaminationthereof. Generally, the FP coating is applied before the sealing layer.This FP offers additional environmental protections and, by use of adistinctive colour, clear visibility on gasket installation when inusage. Advantageously, the covering of the outer edges by the FP polymerallows the user to see which flanges contain this gasket, and whichflanges do not without opening the flange.

In one embodiment, the FP applied is IP9286 Red available from, forexample, Indestructible Paint Ltd.

Attention is directed to all papers and documents which are filedconcurrently with or previous to this specification in connection withthis application and which are open to public inspection with thisspecification, and the contents of all such papers and documents areincorporated herein by reference.

All of the features disclosed in this specification (including anyaccompanying claims, abstract and drawings), and/or all of the steps ofany method or process so disclosed, may be combined in any combination,except combinations where at least some of such features and/or stepsare mutually exclusive.

Each feature disclosed in this specification (including any accompanyingclaims, abstract and drawings) may be replaced by alternative featuresserving the same, equivalent or similar purpose, unless expressly statedotherwise. Thus, unless expressly stated otherwise, each featuredisclosed is one example only of a generic series of equivalent orsimilar features.

The invention is not restricted to the details of the foregoingembodiment(s). The invention extends to any novel one, or any novelcombination, of the features disclosed in this specification (includingany accompanying claims, abstract and drawings), or to any novel one, orany novel combination, of the steps of any method or process sodisclosed.

1. A gasket for sealing two mating surfaces comprising: a) an outerportion comprising (i) a core and (ii) two sealing layers, wherein thecore is between and adjacent to the two sealing layers, wherein one orboth of the core and the sealing layers define an inner edge of theouter portion, and wherein the inner edge defines a first aperture inthe outer portion; b) an inner portion comprising: (i) a deformablematerial; (ii) an inner edge defining a second aperture; and (iii) anouter region secured to the inner edge of the outer portion, wherein theinner portion is located within the first aperture, wherein a thicknessof the inner portion is greater than a thickness of the outer portion.2. The gasket of claim 1, wherein the deformable material comprises achemical treatment agent, wherein the chemical treatment agent provideschemical protection to the mating surfaces.
 3. The gasket of claim 1,wherein the core comprises solid metal and includes a series ofserrations formed on facing surfaces thereof.
 4. The gasket of claim 2,wherein the chemical treatment agent comprises a corrosion treatmentagent.
 5. The gasket of claim 4, wherein the chemical treatment agent ispresent in the deformable material in a range of 0.01% to 50% w/w. 6.The gasket of claim 1, wherein the deformable material is morecompressible than the sealing layers.
 7. The gasket of claim 1, whereinthe sealing layers comprise a material selected from the groupconsisting of PTFE, graphite, vermiculite based sealing material,non-asbestos sheet, and a soft metallic face.
 8. The gasket of claim 7,wherein the sealing layers comprise biaxially orientated PTFE.
 9. Thegasket of claim 1, wherein the deformable material comprises PTFE. 10.The gasket of claim 9, wherein the PTFE comprises biaxially orientatedmicrocellular PTFE.
 11. The gasket of claim 2, wherein the deformablematerial further comprises a microcellular structure and is impregnatedwith the chemical treatment agent.
 12. The gasket of claim 2, whereinthe chemical treatment agent comprises a rust inhibitor.
 13. The gasketof claim 12, wherein the rust inhibitor is selected from the groupconsisting of salts of phosphates, molybdates, nitrites, borates,phosphonates, iron chelating agents and sequestering agents.
 14. Amethod of sealing two substantially parallel surfaces, comprising:interposing between the said surfaces a gasket according to claim 1;positioning said gasket between the two substantially parallel surfaces;and securing said parallel surfaces together to thereby deform the innerportion of the gasket against the said parallel surfaces.
 15. A methodof sealing and simultaneously coating/treating mating surfaces with agasket comprising the steps of locating a gasket according to claim 2 onone of the mating surfaces to be sealed and securing the gasket inposition so that the inner ring is compressed and the chemical treatmentagent is delivered to the mating surfaces.
 16. A method of producing agasket according to claim 1 comprising: providing a core according toclaim 1, coating the core on opposed faces with a core sealing layer toprovide an outer portion according to claim 1 and locating a closefitting inner portion according to claims 1 around the inner edge of theouter portion.
 17. The gasket of claim 1, further comprising a handleextension for use in positioning the gasket.
 18. The gasket of claim 17,wherein the extension is removable from the gasket.
 19. A methodaccording to claim 14, wherein at least one of the parallel surfaces hasbeen corroded to such an extent that significant leakage occurs if agasket consisting of only an outer portion according to part (a) ofclaim 1 is secured between the said parallel surfaces.
 20. (canceled)21. The gasket of claim 1, wherein the core comprises at least onecoplanar projection extending from the inner edge of the outer portioninto the inner portion.
 22. The gasket of claim 1, wherein the outerportion is less flexible than the inner portion.
 23. The gasket of claim1, wherein the thickness of the inner portion is greater than thethickness of the outer portion so that in use the inner portion deformsto a greater extent than the outer portion.
 24. A gasket comprising (a)an outer portion comprising (i) top and bottom surfaces connected by anouter edge and an inner edge, wherein the inner edge defines a firstaperture, and (ii) a sealing material adjacent to one or both of the topand bottom surfaces and surrounding the first aperture; and (b) an innerportion comprising a deformable material and comprising (i) an outeredge adjacent to the inner edge of the outer portion, and (ii) an inneredge, wherein the inner edge defines a second aperture; wherein theinner portion has a thickness greater than a thickness of the outerportion.
 25. (canceled)
 26. The gasket of claim 24, wherein the outeredge of the inner portion is continuously close fitting with the inneredge of the outer portion.
 27. The gasket of claim 24, wherein the outeredge of the inner portion overlaps the inner edge of the outer portion.28. The gasket of claim 24, wherein the inner portion is secured to theouter portion.
 29. The gasket of claim 28, wherein the outer portionfurther comprises at least one fixing component to secure the outerportion to the inner portion.
 30. The gasket of claim 29, wherein thefixing component is at least one projection that extends from the inneredge of the outer portion into the inner portion thereby securing theinner portion to the outer portion.
 31. The gasket of claim 24, whereinthe deformable material comprises a chemical treatment agent.
 32. Thegasket of claim 31, wherein the chemical treatment agent comprises acorrosion inhibitor.
 33. The gasket of claim 31, wherein the chemicaltreatment agent comprises a rust inhibitor.
 34. The gasket of claim 33,wherein the rust inhibitor is selected from the group consisting ofsalts of phosphates, molybdates, nitrates, borates, phosphonates, ironchelating agents and sequestering agents.
 35. The gasket of claim 31,wherein the chemical treatment agent is present in an amount of from0.01% to 50% by weight of the inner portion.
 36. The gasket of claim 24,wherein the sealing material is selected from the group consisting ofPTFE, graphite, vermiculite based sealing material, non-asbestos sheet,and soft metallic face.
 37. The gasket of claim 36, wherein the sealingmaterial is biaxially oriented PTFE.
 38. The gasket of claim 24, whereinthe deformable material comprises PTFE.
 39. The gasket of claim 38,wherein the PTFE comprises biaxially oriented microcellular PTFE. 40.The gasket of claim 24, wherein the inner portion is more compressiblethan the sealing material.
 41. The gasket of claim 24, furthercomprising serrations on one or both of the top surface and the bottomsurface of the outer portion and surrounding the first aperture.
 42. Thegasket of claim 24, further comprising a handle extension for use inpositioning the gasket, wherein the handle extension is removablyattached to the outer portion of the gasket and configured to extendoutside a surface to be sealed.
 43. The gasket of claim 1, wherein theouter region of the inner portion overlaps the inner edge of the outerportion and is secured to upper and lower surfaces thereof.
 44. Thegasket of claim 24, wherein the outer region of the inner portionoverlaps the inner edge of the outer portion and is secured to upper andlower surfaces thereof.
 45. The gasket of claim 1, wherein the innerportion has a compressibility of 30-90%.
 46. The gasket of claim 24,wherein the inner portion has a compressibility of 30-90%.
 47. Thegasket of claim 1, wherein both the core and sealing layers define aninner edge of the outer portion.